As robots slowly take over Amazon’s warehouses, are they causing more harm than good?

Guess who’s getting used to working with robots in their everyday lives? The very same warehouse workers once predicted to be losing their jobs to mechanical replacements.

But doing your job side-by-side with robots isn’t easy. According to their makers, the machines should take on the most mundane and physically strenuous tasks. In reality, they’re also creating new forms of stress and strain in the form of injuries and the unease of working in close quarters with mobile half-ton devices that direct themselves.

“They weigh a lot,” Amazon worker Amanda Taillon says during the pre-Christmas rush at a company warehouse in Connecticut. Nearby, a fleet of 6ft-tall roving robot shelves zipped around behind a chain-link fence.

Taillon’s job is to enter a cage and tame Amazon’s wheeled warehouse robots for long enough to pick up a fallen toy or relieve a traffic jam. She straps on a light-up utility belt that works like a superhero’s force field, commanding the nearest robots to abruptly halt and the others to slow down or adjust their routes.

Amazon and its rivals are increasingly requiring warehouse employees to get used to working with robots. The company now has more than 200,000 robotic vehicles it calls “drives” that are moving goods through its delivery fulfillment centres around the US. That’s double the number it had last year and up from 15,000 units in 2014.

Without these fast-moving pods, robotic arms and other forms of warehouse automation, retailers say they wouldn’t be able to fulfill consumer demand for packages that can land on doorsteps the day after you order them online.

But while fears that robots will replace human workers haven’t come to fruition, there are growing concerns that keeping up with the pace of the latest artificial intelligence technology is taking a toll on human workers’ health, safety and morale.

Warehouses powered by robotics and AI software are leading to human burnout by adding more work and upping the pressure on workers to speed up their performance, says Beth Gutelius, who studies urban economic development at the University of Illinois at Chicago and has interviewed warehouse operators around the US.

Much of the boom in warehouse robotics has its roots in Amazon’s $775m (£591m) purchase of Massachusetts start-up Kiva Systems in 2012. The tech giant rebranded it as Amazon Robotics and transformed it into an in-house laboratory that for seven years has been designing and building Amazon’s robot armada.

Amazon’s Kiva purchase “set the tone for all the other retailers to stand up and pay attention”, says Jim Liefer, CEO of San Francisco start-up Kindred AI, which makes an artificially intelligent robotic arm that grasps and sorts items for retailers such as The Gap.

A rush of venture capital and private sector investment in warehouse robotics spiked to $1.5bn (£1.1bn) a year in 2015 and has remained high ever since, says Rian Whitton, a robotics analyst at ABI Research.

Canadian e-commerce company Shopify spent $450m (£343m) this fall to buy Massachusetts-based start-up 6 River Systems, which makes an autonomous cart nicknamed Chuck that can follow workers around a warehouse. Other mobile robot startups are partnering with delivery giants such as FedEx and DHL or retailers such as Walmart.

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